Durable Thermoregulating Textile Structures and Methods of Manufacture

ABSTRACT

A textile structure including one or more layers of warp yarns interwoven with one or more layers of weft yarns, a durable thermoregulating coating, and a binder that chemically bonds the durable thermoregulating coating to the textile structure. The warp yarns and/or weft yarns include polyester yarns. A method for manufacturing a textile structure includes weaving one or more layers of warp yarns with one or more layers or weft yarns to form a woven textile structure, brushing the textile structure at least two times, applying a binder to the textile structure, and applying a durable thermoregulating coating to the textile structure such that the binder chemically bonds the durable thermoregulating coating to the textile structure. The method may also include heat setting and curing the textile structure to fix the durable thermoregulating coating permanently onto the textile structure.

RELATED APPLICATIONS

This non-provisional application claims priority of U.S. ProvisionalPatent Application No. 62/538,299, filed Jul. 28, 2017 and titled“Durable Thermoregulating Textile Structures and Methods ofManufacture,” the disclosures of which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

Embodiments of the present disclosure relate to textile structures andtheir methods of manufacture thereof. More specifically, the presentdisclosure relates to textile structures for use in the hospitalityindustry.

BACKGROUND

Comfort is a pleasant state of psychological, physiological and physicalharmony between the human being and the environment. The processesinvolved in human comfort are physical, thermophysiological,neuro-physiological and psychological. Thermo-physiological comfort isassociated with the thermal balance of the human body, which strives tomaintain a constant body core temperature of about 37° C. and a rise orfall of ˜±5° C. can be fatal. Hypothermia and hyperthermia may result,respectively, due to the deficiency or excess of heat in the body, whichis considered to be a significant factor in limiting work performance.

In a regular atmospheric condition and during normal activity levels,the heat produced by the metabolism is liberated to the atmosphere byconduction, convection and radiation and the body perspires in vaporform to maintain the body temperature. However, at higher activitylevels and/or at higher atmospheric temperatures, the production of heatis very high and for the heat transmission from the skin to theatmosphere to decrease, the sweat glands are activated to produce liquidperspiration as well. The vapor form of perspiration is known asinsensible perspiration and the liquid form as sensible perspiration.When the perspiration is transferred to the atmosphere, it carries heat(latent as well as sensible) thus reducing the body temperature.Therefore, any textile structure that comes in contact with the humanbody should allow the perspiration to pass through, otherwise it willresult in discomfort. The perception of discomfort in the active casedepends on the degree of skin wetness. During sweating, if the clothingmoisture transfer rate is slow, the relative and absolute humiditylevels of the clothing microclimate will increase, suppressing theevaporation of sweat. This may increase body temperatures, resulting inheat stress.

It is also important to reduce the degradation of thermal insulationcaused by moisture build-up. If the ratio of evaporated sweat andproduced sweat is very low, moisture will be accumulated in the innerlayer of the textile structure, thus reducing the thermal insulation andcausing unwanted loss in body heat. Therefore, both in hot and coldweather and during normal and high activity levels, moisturetransmission through fabrics plays a major role in maintaining thewearer's body at comfort. Hence, a clear understanding of the role ofmoisture transmission through textile structures in relation to bodycomfort is essential for designing high performance textile structuresfor specific applications.

SUMMARY

Embodiments of the present disclosure relate to textile structures andtheir methods of manufacture thereof. More specifically, the presentdisclosure relates to textile structures for use in the hospitalityindustry.

Accordingly, one example embodiment is a textile structure including oneor more layers of warp yarns interwoven with one or more layers of weftyarns, and a durable thermoregulating coating. The durablethermoregulating coating may include at least one of an adaptive agent,a cleaning agent, a fabric softener, an antistatic agent, and citricacid. The thermoregulating coating may include about 30-50 gram perliter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC,both supplied by HeiQ in Switzerland. The textile structure may furtherinclude a binder that may be selected from the group consisting oflatex, elastomeric, acrylic binders, vinyl acrylic binders, vinylacetate binders, styrene containing binders, butyl containing binders,starch binders, polyurethane binders, and polyvinylalcohol containingbinders. The warp yarns have a warp density of about 100 to 120 epi, andmay have a maximum linear mass density of at least about 75 denier withmultiples of about 72 filaments per yarn. The weft yarns have a weftdensity of about 65 to 80 ppi, and may have a minimum linear massdensity of at least about 150 denier with multiples of about 72filaments per yarn. The number of filaments, however, is always morethan the denier of each weft yarn.

Another example embodiment is a method for manufacturing a textilestructure. The method includes weaving one or more layers of warp yarnswith one or more layers or weft yarns to form a woven textile structure,and applying a durable thermoregulating coating to at least a portion ofthe textile structure. The method may also include brushing the textilestructure at least two times, prior to applying the thermoregulatingcoating, to create a fuzzy and softer feel. Brushing increases thesurface area for better absorption and adhesion of the thermoregulatingcoating on the fabric. The method may also include heat setting andcuring the textile structure to fix the durable thermoregulating coatingpermanently onto the textile structure. The durable thermoregulatingcoating may include at least one of an adaptive agent, a cleaning agent,a fabric softener, an antistatic agent, and citric acid. Thethermoregulating coating may include about 30-50 gram per liter ofAdaptive AC-03, and about 1-10 gram per liter of Clean DEC, bothsupplied by HeiQ in Switzerland. The textile structure may furtherinclude a binder that may be selected from the group consisting oflatex, elastomeric, acrylic binders, vinyl acrylic binders, vinylacetate binders, styrene containing binders, butyl containing binders,starch binders, polyurethane binders, and polyvinylalcohol containingbinders. The warp yarns have a warp density of about 100 to 120 epi, andmay have a maximum linear mass density of at least about 75 denier withmultiples of about 72 filaments per yarn. The weft yarns have a weftdensity of about 65 to 80 ppi, and may have a minimum linear massdensity of at least about 150 denier with multiples of about 72filaments per yarn. The number of filaments, however, is always morethan the denier of each weft yarn.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

The foregoing aspects, features, and advantages of embodiments of thepresent disclosure will further be appreciated when considered withreference to the following description of embodiments and accompanyingdrawings. In describing embodiments of the disclosure illustrated in theappended drawings, specific terminology will be used for the sake ofclarity. However, the disclosure is not intended to be limited to thespecific terms used, and it is to be understood that each specific termincludes equivalents that operate in a similar manner to accomplish asimilar purpose.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the discussion of the described embodiments ofthe invention. Additionally, elements in the drawing figures are notnecessarily drawn to scale. For example, the dimensions of some of theelements in the figures may be exaggerated relative to other elements tohelp improve understanding of embodiments of the present invention. Likereference numerals refer to like elements throughout the specification.

FIG. 1 illustrates example steps in a method for manufacturing a textilestructure, according to one or more example embodiments.

FIG. 2 illustrates the adaptive nature of the durable thermoregulatingtextile structure, according to one or more example embodiments.

FIGS. 3A-3C illustrate how quickly the heat dissipates in the durablethermoregulating textile structure, according to one or more exampleembodiments.

FIGS. 4A-4B illustrate how coolness may be equalized in the durablethermoregulating textile structure, according to one or more exampleembodiments.

DETAILED DESCRIPTION

Example embodiments relate to a woven polyester structure thatdynamically responds to body temperature to keep one cool when they feelhot and keeps them warm when they feel cold. The thermoregulating aspectof the disclosure may be used in bedding products such as flat sheets,fitted sheets, pillowcases, pillow protectors, shells of pillows, shellsof comforters, etc.

Turning now to the figures, FIG. 1 illustrates example steps in a method100 for manufacturing a textile structure, according to one or moreexample embodiments. The method 100 includes weaving one or more layersof warp yarns with one or more layers or weft yarns to form a woventextile structure, at step 102. The warp yarns can have a warp densityof about 100 to 120 epi, and may have a maximum linear mass density ofat least about 75 denier with multiples of about 72 filaments per yarn.The weft yarns can have a weft density of about 65 to 80 ppi, and mayhave a minimum linear mass density of at least about 150 denier withmultiples of about 72 filaments per yarn. The number of filaments,however, is always more than the denier of each weft yarn. Both warp andweft yarns may include yarns made of a polymeric material, such aspolyester. While polyester is preferred, the structure may include anysynthetic fiber that may be suitable for the purpose.

After the woven textile structure is formed, at step 104, the structureis mechanically brushed at least two times at room temperature. Thisprocess may be carried out at about 30 m/min speed to create a fuzzy andsofter feel on the fabric. In the next step 106, the fabric may bepassed through an alkali refining process where the alkali solution mayinclude an alkali (5-10% of fabric weight), such as NaOH, one or morecleaning agents (1-2% of fabric weight), hydrogen peroxide (1-5% offabric weight), and a chelating agent of about 0.5 gram per liter of thesolution. The cleaning agent may include a soil release agent and/or awetting agent. The pH value of this solution may be about 8-9, and witha pick-up of about 90-100% the fabric is run through this solution atabout 100 m/min at an elevated temperature of about 130° C. After thealkali refining step 106, the fabric is bleached, at step 108, using ableaching solution including a brightening agent of about 16 gram perliter of the solution, and an alkali (about 1% of fabric weight), suchas NaOH. The pH value of this solution may be about 8-9, and with apick-up of about 90-100% the fabric is run through this solution atabout 100 m/min at an elevated temperature of about 130° C. After thefabric is bleached, it enters a washing zone, at step 110, where asteamer at 70-80° C. temperature steams the fabric with a solutionhaving a pH of about 7-7.5. The fabric may be run through this sectionat about a reduced speed of 40 m/min.

The method further includes, at step 114, applying a durablethermoregulating coating to at least a portion of the textile structure.The durable thermoregulating coating may include one or more polymersmixed in an aqueous solution. For example, the durable thermoregulatingcoating may include an adaptive agent (HeiQ Ac-03) in the amount of30-50 gram per liter of the solution, a cleaning agent (HeiQ Clean DEC)in the amount of 1-10 gram per liter, a fabric softener of about 5 gramper liter, an antistatic agent of about 5 gram per liter, and a citricacid of about 0.05 gram per liter. The adaptive agent may include, amongother things, 0.5-1% triisobutyl phosphate, and 0.2-0.5% ethoxylated andpropoxylated alcohols. The cleaning agent may include a soil releaseagent and/or a wetting agent. The cleaning agent may include, amongother things, 30-50% isotrideceth 12, 10-15% 2-(2-butoxyethoxy)ethanol,2-3% N-(2-Ethylhexyl)isononan-1-amide, and 1-2%Poly(oxy-1,2-ethanediyl), a-butyl-uJ-hydroxy. The solution may have a pHof about 5-7, and the fabric may be run through this solution at a speedof about 60 m/min at an elevated temperature of 190-200° C.

The method may optionally include, at step 112, applying a binder priorto application of the durable thermoregulating coating. The binder maybe selected from the group consisting of latex, elastomeric, acrylicbinders, vinyl acrylic binders, vinyl acetate binders, styrenecontaining binders, butyl containing binders, starch binders,polyurethane binders, and polyvinylalcohol containing binders. Themethod may also include, at step 116, heat setting and curing thetextile structure to fix the durable thermoregulating coatingpermanently onto the textile structure. After the fabric goes throughthe heat setting and the finishing process, the fabric may be vacuumcleaned at a speed of about 30-40 m/min, at step 118. The resultingfabric can be cut and sewn to form, among other things, a sheetingfabric for use in the hospitality industry. However, thethermoregulating aspect of the disclosure may be also used in otherbedding products such as flat sheets, fitted sheets, pillowcases, pillowprotectors, shells of pillows, shells of comforters, etc.

Accordingly, one example embodiment is a woven polyester structure thatdynamically responds to body temperature to keep one cool when they feelhot and keeps them warm when they feel cold. The durablethermoregulating textile structure may be produced by weaving polyestermicrofilaments in an optimized ratio in warp and weft directions.Adaptive AC-03, a chemical from Swiss supplier HeiQ, may be used forfinishing such a woven structure. It shows opposite, “non-Newtonian”behavior. The structure has high moisture affinity at low temperatures(moisture capture) and low moisture affinity at high temperatures(moisture release).

Durable thermoregulating textile structures according to exampleembodiments disclosed can withstand at least 100 commercial washes. Astrong binder that molecularly bonds the polyester filaments to theAC-03 chemical may be used. The binder may be colorless and may not makethe hand of the fabric stiff or rough.

The durable thermoregulating fabric may be woven with polyester yarns,which may include filaments or multifilaments, with a warp density ofabout 100 to 120 epi. Each polyester yarn may have a maximum linear massdensity of at least about 75 denier with multiples of about 72 filamentsper yarn. The durable thermoregulating fabric may also include polyesteryarns, which may include filaments or multifilaments, in the weftdirection. The weft density of the textile structure may be anywherefrom about 65 to 80 ppi. Each polyester yarn may have a minimum linearmass density of at least about 150 denier with multiples of about 72filaments per yarn. The number of filaments, however, is always morethan the denier of each weft yarn. Warp and weft yarns may be interwovenin any known pattern, including but not limited to plain, twill, satin,and sateen. The woven textile structure may be brushed, using forexample a mechanical process similar to napping, to create a fuzzy andsofter feel. This process also minimizes the undesirable sheen inherentto most synthetic fibers.

After the fabric is padded through a solution of binder, the fabric maybe run through the AC-03 solution. The binder may include any binderincluding but not limited to latex, elastomeric, and acrylic binders.Acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrenecontaining binders, butyl containing binders, starch binders,polyurethane binders, and polyvinylalcohol containing binders areexamples of binders that find utility in coating and finishing thefabric. Then the fabric is heat set and cured to fix the chemicalpermanently onto the fabric. The resultant polyester fabric is now adurable thermoregulating fabric.

FIG. 2 illustrates the adaptive nature of the durable thermoregulatingtextile structure 202, according to one or more example embodiments. Asillustrated in the figure, the thermoregulating coating becomes liquidwith decrease in temperature (204), and becomes solid with increase intemperature (206). A fabric or textile structure 202 treated with thisdurable thermoregulating coating absorbs water vapor and swells at lowertemperatures, thereby giving a warming effect to the body, and releaseswater vapor and collapses at higher temperatures, thereby giving acooling effect to the body. FIGS. 3A-3C, which are thermographic imagesof a sheeting fabric with the durable thermoregulating coating,illustrate how quickly the heat dissipates in the durablethermoregulating textile structure, according to one or more exampleembodiments. In these figures, the left hand rests on a control(untreated) fabric while the right hand rests on a fabric that istreated with the thermoregulating coating. It can be noticed here thatas time passes, the right side cools faster than the left (untreatedfabric) due to faster dissipation of heat in treated fabric. The imagesshown in FIG. 3A-3C are taken at 1 min intervals, and it can be seenhere that the center of the palms, which is at about 90° F., cools downto about 80° F. within a span of about 2 mins on the thermoregulatingside.

FIGS. 4A-4B illustrate how coolness may be equalized in the durablethermoregulating textile structure, according to one or more exampleembodiments. The images shown in FIG. 4A-4B are taken at 1 minintervals, and it can be seen here that the center of the impression,which is at about 70° F., cools down to about 65° F. within a span ofabout 1 min on the thermoregulating side. Here, two equally cold metalobjects were placed on the left (control) and right side (treated). Itcan be noticed here that the dissipation of cold is faster in thethermoregulating fabric when compared to untreated fabric.

Evaluation of the Textile Structure

Two fabric types were tested by the Textile Protection and ComfortCenter (T-PACC) in the College of Textiles at North Carolina StateUniversity. An advanced sweating manikin system and thermal imagingcamera were used to evaluate and compare the response of the two fabrictypes. Test samples were tested at the TPACC testing facility. Amattress was covered with two sheets split vertically down the middleand tested with the sweating thermal manikin system. Fabric types wereidentified as Control (untreated fabric) and Phasology (fabric treatedwith durable thermoregulating coating), respectively. No clothing wasworn during testing. A comforter was used during testing. The comforterconsisted of 95% white duck feathers/5% white duck down in a 100%polyester cover. The weight of the comforter was about 16.3 oz/yd². Themattress cover was tested on a twin mattress in the test chamber.

The sweating manikin system is a “Newton” type instrument designed toevaluate heat and moisture management properties of clothing systems.This instrument simulates heat and sweat production making it possibleto assess the influence of clothing on the thermal comfort process for agiven environment. Simultaneous heat and moisture transport through theclothing system, and variations in these properties over different partsof the body can be quantified.

The manikin consists of several features designed to work together toevaluate clothing comfort and/or heat stress. Housed in aclimate-controlled chamber, the manikin surface is divided into 34separate sections, each of which has its own sweating, heating, andtemperature measuring system. With the exception of a small portion ofthe face, the whole manikin surface can continuously sweat.

Using a pump, preheated water is supplied from a reservoir locatedoutside of the environmental chamber. An internal sweat control systemdistributes moisture to 139 “sweat glands” distributed across thesurface of the manikin. Water supplied to the simulated sweat glands iscontrolled by operator entry of the desired sweat rate. Each sweat glandis individually calibrated and the calibration values are used by thecontrol software to maintain the sweat rate of each body section. Waterexuding from each simulated sweat gland is absorbed by a custom madebody suit. This specialty designed suit acts as the manikin's ‘skin’during sweating tests. It is form-fitted to the manikin to eliminate airgaps and provides wicking action to evenly distribute moisture acrossthe entire manikin surface.

Continuous temperature control for the 34 body segments is accomplishedby a process control unit that uses analog signal inputs from separateResistance Temperature Detectors (RTDs). These evenly distributed RTDsare used instead of point sensors because they provide temperaturemeasurements in a manner such that all areas are equally weighted.Distributed over an entire section, each RTD is embedded just below thesurface and provides an average temperature for each section. Softwareestablishes any discrepancy between temperature set point and the inputsignal, and adjusts power to section heaters as needed. Temperaturecontrols are adjustable, by the operator, for each heater control.

The Newton sweating manikin system combined with ManikinPC2 controlsystem allows the manikin to simulate human metabolism andthermoregulation while performing a variety of activities. The softwareand manikin interact in real-time setting imitating the transientbehavior of the human body and allowing for the most accuratepredictions of human physiological responses that can be achievedwithout actual human trials. The ManikinPC2 model control system is usedto predict human physiological response including average skintemperature, final temperature of each manikin section, predicted corebody temperature, as well as other parameters.

The FLIR A325 Infrared Camera is used to record thermographic imageswith temperature measurement. These non-contact temperature measurementsallow for surface temperature evaluation of test items withoutinterfering with the test operation. ThermoVision ExaminIR AnalysisSoftware is used to read and analyze thermal images.

The purpose of this test was to evaluate the effectiveness of Phasologytreatment on sheeting fabric compared to an untreated control fabric.The response of the fabric was assessed by use of a thermal imagingcamera and manikin measurements. The two fabric types were taped into asingle split-fabric mattress cover. Simultaneous evaluation of the twofabric types was accomplished by having the split-fabric mattress coverdesign that the manikin could be equally exposed to each side. Theexcess fabric was folded over top the manikin and taped at the seam. Themanikin was dressed in the typical sweating skin material to assist withsweat wicking and spreading as well as a water vapor permeable/liquidwater impermeable suit to limit the amount of liquid water pooling intothe mattress. Test protocols were determined that used physiologicalmodel control of the manikin in which the manikin responded to the testenvironment and simulated sleeping condition based on a humanthermoregulation model. The test environment was relatively mild. Themattress was tested once (Control right side/Phasology left side) perTest Protocol 1 (See Table 2). Table 1 shows the testingconditions/parameters used.

TABLE 1 Testing Parameters Parameter Value Position/Movement Horizontalon mattress/static Sweat Rate Varying based on physiological modelcontrol Manikin Mode Physiological Model Control Skin Temperature Modelpredicted Heat Flux Model dependent: metabolic rate = 0.95 MET ChamberTemperature 24° C. Chamber Humidity 50% Airflow 0.4 m/s Test ArticlesSplit Treated/Untreated Sheet

TABLE 2 Test Protocol Test Protocol 1. Lay manikin on bed on top ofsheeting fabric 2. Place comforter on manikin and add compression withweights to simulate human weight (~150 lbs.) 3. Start model control 4.Run manikin 3 hours in physiological model control mode 5. Remove weightand comforter from manikin 6. Record IR image of manikin immediatelyafter testing is complete 7. Lift manikin off bed 8. Record IR image ofsheeting fabric immediately after manikin is lifted off bed 9. Record IRimage every 30 sec for 10 minutes 10. End Test

Table 3 shows the average surface temperature and change in surfacetemperature from the defined Region of Interest (ROI). ΔT is defined as(T-Ti) and Time 0 is the time immediately after removing the manikinfrom the mattress.

TABLE 3 Average Surface Temperatures for mattress ROIs Control PhasologyControl Phasology Time T (° C.) T (° C.) ΔT (° C.) ΔT (° C.) 0 26.9 27.80.0 0.0 5 23.4 22.9 −3.4 −4.8 10 23.1 22.3 −3.8 −5.4

Moisture Management Test (MMT)

The fabric was conditioned and tests were performed in the standardatmosphere laboratory condition of 70+3° F. (21° C.), 65+5% RH. The MMTis a system that can measure liquid transport properties of fabrics. Aspecific volume of electrically conductive fluid is injected onto thefabric surface at a controlled rate, and a series of conductive, copperrings monitor the movement of this fluid. The conductivity of the samplecontinuously changes as the fluid moves throughout the sample, and thisdata is recorded in order to determine the moisture managementproperties of the sample.

For the purpose of this test, the side of the fabric that contacts theskin is referred to as the “top surface,” and the other side is referredto as the “bottom surface.” The reported measurements include:

Wetting Time (s): WTT (top surface) and WTB (bottom surface)—period inwhich the top and bottom surfaces just start to get wetted

Absorption Rate (%/s): ART (top surface) and ARB (bottom surface)—theaverage moisture absorption ability of the top and bottom surfaces

Maximum Wetted Radius (mm): MWRT (top surface) and MWRB (bottomsurface)—the maximum wetted ring radius at the top and bottom surface

Spreading Speed (mm/s): SST (top surface) and SSB (bottom surface)—theaccumulative spreading speed from the center to the maximum wettedradius

The reported parameters calculated from the above measurements include:

One-way Transport Capability (%): R—the difference of the accumulativemoisture content between the two surfaces of the fabric.

Overall Moisture Management Capacity: OMMC—an index to measure theoverall capability of the fabric to manage the transport of liquidmoisture based on three aspects of performance.

The results of these tests are summarized below (Table 4). Individualmetrics were evaluated as well as two indices that quantify the moisturemanagement properties of fabric, (One-way Transport Capability, andOverall Moisture Management Capacity). A higher value for either ofthese indices indicates a greater capability to effectively transportliquids. The results illustrate that even after 100 wash cycles, theoverall moisture management capacity of the fabric is virtuallyunchanged.

TABLE 4 Moisture Management Summary Sample Max Max Wetting WettingAbsorption Absorption Wetted Wetted Spreading Spreading Overall Time -Time - Rate - Rate - Radius - Radius - Speed - Speed - Moisture TopBottom Top Bottom Top Bottom Top Bottom Management (sec) (sec) (%/sec)(%/sec) (mm) (mm) (mm/sec) (mm/sec) Capacity Unwashed 2.4 2.5 68.2 70.030.0 30.0 7.3 7.1 0.5 (P = 0) 100x 2.5 2.6 53.4 60.8 30.0 30.0 7.3 7.20.6 Washed (P = 100)

A grading table is provided by SDL Atlas, manufacturers of the MMTdevice. These data, obtained under controlled laboratory conditions,characterize the moisture management properties of test sample responsesin laboratory conditions.

Grade Index 1 2 3 4 5 Wetting Top >=120  20~119  5~19 3~5 <3 Time (see)No Wetting Slow Medium Fast Very Fast Bottom >=120  20~119  5~19 3~5 <3No Wetting Slow Medium Fast Very Fast Absorption Rate Top  0~10 10~3030~50  50~100 >100  (%/sec) Very Slow Slow Medium Fast Very Fast Bottom 0~10 10~30 30~50  50~100 >100  Very Slow Slow Medium Fast Very Fast MaxWetted Top 0~7  7~12 12~17 17~22 >22  Radius No Wetting Small MediumFast Very Fast (mm) Bottom 0~7  7~12 12~17 17~22 >22  No Wetting SmallMedium Fast Very Fast Spreading Top 0~1 1~2 2~3 3~4 >4 Speed Very SlowSlow Medium Fast Very Fast (mm/sec) Bottom 0~1 1~2 2~3 3~4 >4 Very SlowSlow Medium Fast Very Fast OMMC   0~0.2 0.2~0.4 0.4~0.6 0.6~0.8   >0.8Very Poor Poor Good Very Good Excellent

Accordingly, one example embodiment is a textile structure including oneor more layers of warp yarns interwoven with one or more layers of weftyarns, and a durable thermoregulating coating. The durablethermoregulating coating may include at least one of an adaptive agent,a cleaning agent, a fabric softener, an antistatic agent, and citricacid. The cleaning agent may include a soil release agent and/or awetting agent. The thermoregulating coating may include about 30-50 gramper liter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC,both supplied by HeiQ in Switzerland. The textile structure may furtherinclude a binder that may be selected from the group consisting oflatex, elastomeric, acrylic binders, vinyl acrylic binders, vinylacetate binders, styrene containing binders, butyl containing binders,starch binders, polyurethane binders, and polyvinylalcohol containingbinders. The warp yarns have a warp density of about 100 to 120 epi, andmay have a maximum linear mass density of at least about 75 denier withmultiples of about 72 filaments per yarn. The weft yarns have a weftdensity of about 65 to 80 ppi, and may have a minimum linear massdensity of at least about 150 denier with multiples of about 72filaments per yarn. The number of filaments, however, is always morethan the denier of each weft yarn.

Another example embodiment is a method for manufacturing a textilestructure. The method includes weaving one or more layers of warp yarnswith one or more layers or weft yarns to form a woven textile structure,and applying a durable thermoregulating coating to at least a portion ofthe textile structure. The method may also include brushing the textilestructure at least two times, prior to applying the thermoregulatingcoating, to create a fuzzy and softer feel. Brushing increases thesurface area for better absorption and adhesion of the thermoregulatingcoating on the fabric. The method may also include heat setting andcuring the textile structure to fix the durable thermoregulating coatingpermanently onto the textile structure. The durable thermoregulatingcoating may include at least one of an adaptive agent, a cleaning agent,a fabric softener, an antistatic agent, and citric acid. Thethermoregulating coating may include about 30-50 gram per liter ofAdaptive AC-03, and about 1-10 gram per liter of Clean DEC, bothsupplied by HeiQ in Switzerland. The textile structure may furtherinclude a binder that may be selected from the group consisting oflatex, elastomeric, acrylic binders, vinyl acrylic binders, vinylacetate binders, styrene containing binders, butyl containing binders,starch binders, polyurethane binders, and polyvinylalcohol containingbinders. The warp yarns have a warp density of about 100 to 120 epi, andmay have a maximum linear mass density of at least about 75 denier withmultiples of about 72 filaments per yarn. The weft yarns have a weftdensity of about 65 to 80 ppi, and may have a minimum linear massdensity of at least about 150 denier with multiples of about 72filaments per yarn. The number of filaments, however, is always morethan the denier of each weft yarn.

The Specification, which includes the Summary, Brief Description of theDrawings and the Detailed Description, and the appended Claims refer toparticular features (including process or method steps) of thedisclosure. Those of skill in the art understand that the inventionincludes all possible combinations and uses of particular featuresdescribed in the Specification. Those of skill in the art understandthat the disclosure is not limited to or by the description ofembodiments given in the Specification.

Those of skill in the art also understand that the terminology used fordescribing particular embodiments does not limit the scope or breadth ofthe disclosure. In interpreting the Specification and appended Claims,all terms should be interpreted in the broadest possible mannerconsistent with the context of each term. All technical and scientificterms used in the Specification and appended Claims have the samemeaning as commonly understood by one of ordinary skill in the art towhich this invention belongs unless defined otherwise.

As used in the Specification and appended Claims, the singular forms“a,” “an,” and “the” include plural references unless the contextclearly indicates otherwise. The verb “comprises” and its conjugatedforms should be interpreted as referring to elements, components orsteps in a non-exclusive manner. The referenced elements, components orsteps may be present, utilized or combined with other elements,components or steps not expressly referenced.

Conditional language, such as, among others, “can,” “could,” “might,” or“may,” unless specifically stated otherwise, or otherwise understoodwithin the context as used, is generally intended to convey that certainimplementations could include, while other implementations do notinclude, certain features, elements, and/or operations. Thus, suchconditional language generally is not intended to imply that features,elements, and/or operations are in any way required for one or moreimplementations or that one or more implementations necessarily includelogic for deciding, with or without user input or prompting, whetherthese features, elements, and/or operations are included or are to beperformed in any particular implementation.

The textile structures and methods described herein, therefore, are welladapted to carry out the objects and attain the ends and advantagesmentioned, as well as others inherent therein. While example embodimentsof the textile structure and method have been given for purposes ofdisclosure, numerous changes exist in the details of procedures foraccomplishing the desired results. These and other similar modificationsmay readily suggest themselves to those skilled in the art, and areintended to be encompassed within the spirit of the textile structureand method disclosed herein and the scope of the appended claims.

1. A textile structure comprising: one or more layers of warp yarnsinterwoven with one or more layers of weft yarns, wherein the warp yarnsor weft yarns comprise polyester yarns; and a thermoregulating coatingapplied on at least a portion of the textile structure.
 2. The textilestructure of claim 1, wherein the thermoregulating coating comprises atleast one of an adaptive agent, a cleaning agent, a fabric softener, anantistatic agent, and citric acid.
 3. The textile structure of claim 1,wherein the thermoregulating coating comprises about 30-50 gram perliter of the adaptive agent.
 4. The textile structure of claim 1,wherein the thermoregulating coating comprises about 1-10 gram per literof the cleaning agent.
 5. The textile structure of claim 1, furthercomprising a binder that chemically bonds the thermoregulating coatingto the textile structure.
 6. The textile structure of claim 1, whereinthe binder may include at least one of latex, elastomeric, acrylicbinders, vinyl acrylic binders, vinyl acetate binders, styrenecontaining binders, butyl containing binders, starch binders,polyurethane binders, and polyvinylalcohol containing binders.
 7. Thetextile structure of claim 1, wherein the weight per square unit of thetextile structure is at least 80 gram per square meter.
 8. The textilestructure of claim 1, wherein the warp yarns have a warp density ofabout 100 to 120 epi.
 9. The textile structure of claim 1, wherein thewarp yarns have a maximum linear mass density of at least about 75denier.
 10. The textile structure of claim 1, wherein the weft yarnshave a weft density of about 65 to 80 ppi.
 11. The textile structure ofclaim 1, wherein the weft yarns have a minimum linear mass density of atleast about 150 denier.
 12. The textile structure of claim 1, whereinthe warp yarns and the weft yarns comprise polyester yarns.
 13. Thetextile structure of claim 1, wherein the textile structure comprises asheeting fabric for use in the hospitality industry.
 14. A method formanufacturing a textile structure, the method comprising: weaving one ormore layers of warp yarns with one or more layers or weft yarns to forma woven textile structure, wherein the warp yarns or weft yarns comprisepolyester yarns; and applying one or more layers of a thermoregulatingcoating to the textile structure.
 15. The method of claim 14, furthercomprising: brushing the textile structure two or more times prior toapplying the one or more layers of the thermoregulating coating.
 16. Themethod of claim 14, wherein the thermoregulating coating comprises atleast one of an adaptive agent, a cleaning agent, a fabric softener, anantistatic agent, and citric acid.
 17. The method of claim 14, whereinthe thermoregulating coating comprises about 30-50 gram per liter of theadaptive agent.
 18. The method of claim 14, wherein the thermoregulatingcoating comprises about 1-10 gram per liter of the cleaning agent. 19.The method of claim 14, further comprising: heat setting and curing thetextile structure to permanently fix the thermoregulating coating ontothe textile structure.
 20. The method of claim 14, further comprising:applying one or more layers of a binder, prior to applying the one ormore layers of the thermoregulating coating and after the brushing step,wherein the binder chemically bonds the thermoregulating coating to thetextile structure.